A U.S. air safety investigation has identified metal fatigue in an engine component as responsible for a July incident on a Ryanair flight where engine debris shattered a cabin window and partially pulled a passenger outside.
The National Transportation Safety Board (NTSB) has concluded that metal fatigue in an engine fan blade led to a serious incident aboard a Ryanair flight last month. According to preliminary findings, approximately 37 percent of the fractured blade's surface displayed characteristics consistent with metal fatigue caused by repeated stress concentrated near the blade's root.
The incident occurred on July 10 when a Boeing 737-800 operated by Malta Air, a Ryanair subsidiary, was climbing through 16,000 feet en route from Thessaloniki, Greece, to Memmingen, Germany. Pilots detected a high-vibration alert from the right engine, which rapidly intensified before crew members heard a loud noise and cabin pressure was lost. Fragments from the damaged engine penetrated the fuselage and cabin, destroying a window at row 11.
A 61-year-old passenger seated at the affected window was partially pulled into the opening before cabin crew and other passengers managed to retrieve him. The man sustained neck and shoulder injuries along with friction burns. A physician traveling on the flight provided treatment as the aircraft returned to Thessaloniki. Passengers utilized a galley metal box to help seal the damaged area during descent.
While investigators discovered bird remains and feathers in various engine components, the NTSB has not determined whether a bird strike directly caused the blade failure. Maintenance records indicated the engine had experienced four suspected bird strikes over the previous year. Notably, ultrasonic inspections performed in November 2025 and May 2026 detected no damage to the fan blades. The investigation remains ongoing as officials work to identify underlying causes.
